LED light tubes, light boxes including LED light tubes and methods for installation of LED light tubes in light boxes

ABSTRACT

Light emitting diode (LED) light tubes having rotatable end cap assemblies are described. The LED light tubes include a hollow tube and a circuit board with LED chips thereon. The end cap assemblies are provided on either end of the tube. Each end cap assembly includes a socket cap, a plug having a plug body and at least one connector, and an end cap body, one end of which engages one of the ends of the hollow tube. A cam locking mount that is positioned within the plug body and on the opposite side has projections to be positioned in the bore of the end cap body. A rotation cam is seated in the cam locking mount and provides for controlled rotation of the LED tube relative to the end caps. Methods of installing the LED light tubes in new installations and retrofit installations and for use in sign assemblies are also described.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of co-pending U.S. applicationSer. No. 17/108,659, filed Dec. 1, 2020, and issued as U.S. Pat. No.11,204,136, on 12/21/2021, which is a division of U.S. application Ser.No. 15/968,436, filed May 1, 2018, and issued as U.S. Pat. No.10,833,669, on Jan. 5, 2021.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates to the field of light tubes that are illuminatedby one or more light emitting diode (LED), and particularly to suchlight tubes that have rotatable end cap assemblies for use inadvertising and other outdoor signs, including those in the form of aone- or two-sided light box assembly that may be installed includingsuch LED light tubes to create a new light installation or that may beinstalled in an existing light box installation to retrofit suchinstallation to include such LED light tubes in place of fluorescentlight tubes.

Description of Related Art

Lighting signs are known in the art using fluorescent lighting tubes.The tubes are mounted within a lighting “box” having one side or twosides that are translucent and having a color and/or design thereon,which sides are mounted in a frame. Such signs may be interior orexterior signs, for example, signs used along the road or in a parkinglot area outside a business to advertise a store location or products.Within the frame are side mounting having sockets therein designed forreceiving fluorescent tubes. The tubes can be run horizontally orvertically. The tubes illuminate the inside of the box for exteriorviewing of the designs on the side of the box so they are visible atnight. The fluorescent tubes are connected within the sockets and wiredthrough a ballast and is in connection with existing wiring incommunication with an electrical supply source. Such sign fixtures areknown in the art. Fluorescent light tubes are also used on the interiorof buildings for interior lighting.

Over time, there has been a desire to replace interior fluorescentlighting tubes such as in offices and stores, with LED lighting tubes.LED lighting tubes provide excellent illumination and last far longerthan standard fluorescent bulbs, while using less energy such that therepresent a reduction in energy costs as well. Such tubes can beretrofit into existing indoor lighting mounts within an existing ceilingframe and the light converted. Such innovation in the signage area hasbeen more difficult because of the wiring in an existing light boxassembly, the need to change the socket configurations and the size andweight of the signs as well as the difficulties in re-wiring signs thatare remote from the electrical source. Thus, attempted installations mayrequire taking down a sign, or complex re-wiring, rebuilding orreplacing of the light box of the sign. It is also important to be ableto provide illumination in different directions, particularly fortwo-sided sign light boxes as the sign may be visible from twodirections and/or because if all lights are simply aligned, it can givethe appearance of “striping” within the light instead of lights thatilluminated in varying directions. Thus, there is a need in the art foran LED tube that can be mounted in a new LED ready frame or, morepreferably, in an existing fluorescent tube sign box structure that iseasy to install, does not require all new wiring and can be easilyinstalled without having to remove the lighting box or dismantling it.It would also be useful in the art to have such lights which can bemounted and shine in more than one direction for unique illuminationeffects.

One prior art attempt to create an LED light tube that may be retrofitinto a fluorescent socket for various uses including in an illuminatedsign may be found in U.S. Pat. No. 7,488,086. This patent describes aretro-fit LED tube having a rotatable fitting. The tube is fit into anindependent adaptor which may be plugged into a fluorescent tube socket.The adaptor receives a bi-pin connector from the LED tube on one end andon an opposite end includes its own bi-pin connector for plugging intothe socket. Rotation of the tube may be used to adjust the overalllength of the assembly by compressing an internally rotatable pin socketand the adaptor is used to retro-fit the tube into the existing sockets.

A further retrofit LED tube is disclosed in U.S. Pat. No. 9,851,054. Thetubes described in that patent may be used in place of fluorescent tubesin a light box. A four-sided hollow extruded body may be cut to varioussizes and is alleged to fit snugly around an electrical connectorinstead a standard fluorescent tube socket. LEDs are adhered to sides ofthe body which may be enclosed in a waterproof outer casing sealed onits end.

U.S. Pat. No. 8,066,411 teaches a LED tube that can include rotatableend caps. The rotating end caps include a two prong connector secured toa limiter that rotates within a collet in a measured manner so as torotate up to 190° until a stop is reached. The tubes may be in rotatablesegments. They can be installed in standard fluorescent fixtures byreplacing the fluorescent lamp and the lamp's ballast with LED driverelectronics. Once, installed, the segments of the lamp may be rotated.

While various designs of LED tubes exist including those which aredouble- or multi-sided in terms of their ability to shine LED light,there is still a need in the art for such a tube and method of mountingan LED tube that easily mounts into a sign light box, including in anexisting sign installation, can be rotated to any desired angle forillumination and does not require difficult, complex or very expensiveinstallation steps.

BRIEF SUMMARY OF THE INVENTION

The invention includes sign assemblies, light emitting diode light tubesand a method for installing such tubes, and a method for retrofittinglight emitting diode light tubes in sign assemblies that incorporatefluorescent light tubes.

In one embodiment, the invention includes a sign assembly that includesat least one translucent side plate; a frame structure securing aperimeter of the at least one translucent side plate, the frame havingan interior surface and an exterior surface, wherein the interiorsurface of the frame has at least two opposite sides spaced from eachother; at least one electrical socket; wiring for connecting theelectrical socket to an electrical source; and at least one lightemitting diode light tube.

The at least one light emitting diode light tube in the sign assemblycomprises a hollow tube defining a passageway extending longitudinallytherethrough, the hollow tube having a first end and a second end and anexterior surface; a circuit board having a plurality of light emittingdiode chips mounted thereon, the circuit board mounted on the exteriorsurface of the hollow tube; and a first and a second rotatable end capassembly, each of the first and the second rotatable end cap assembly ismounted respectively on the first end and the second end of the hollowtube.

Each of the first and the second rotatable end caps assembliescomprises: a socket cap defining at least one hole extendinglongitudinally therethrough; a plug having a plug body and at least oneconnector extending longitudinally from an exterior end of the plugbody, wherein the at least one connector is configured to pass throughthe at least one hole in the socket cap and be received within the atleast one electrical socket, the plug body having on an interior endthereof, an interior surface defining an interior space therein; arotatable end cap having an end cap body with a first end and a secondend, the first end of the end cap body configured to engage one of theends of the hollow tube and the second end of the end cap body having aninner surface defining a recess, at least one longitudinally extendingbore extending through the rotatable end cap and through the recess ofthe second end of the end cap body, the bore defining a longitudinalpassageway, and a longitudinally extending collar situated between theinner surface of the rotatable end cap and the longitudinally extendingbore, wherein the plug body is configured to be received at leastpartially within the second end of the rotatable end cap; a cam lockingmount having an exterior facing side configured to be positioned withinthe interior space of the plug body and an interior facing side havinglongitudinally extending projections configured to be received withinthe longitudinally extending bore of the rotatable end cap and to form alongitudinally extending opening between the projections in generalalignment with the longitudinal passageway through the bore of therotatable end cap; a rotation cam having a tubular shape defining apassageway extending therethrough, a first end and a second end, thefirst end positioned in the recess of the second end of the rotatableend cap between the collar and the bore of the rotatable end cap,wherein an inner facing surface of the collar is configured to receiveand engage the first end of the rotation cam, the second end of therotation cam configured to be received within the cam locking mountaround the projections thereof, wherein the rotatable end cap is capableof controlled rotation with respect to the plug body and cam lockingmount by rotation of the rotation cam within the collar, and wherein theconnector of the plug is in electrical communication with the at leastone circuit board.

The sign assembly may include two translucent side plates. A designand/or logo may appear on an exterior facing side of one or more of theat least one translucent side plate. The perimeter of the at least onetranslucent side plate may be shaped as a rectangle or square or othershape as described herein. The frame structure may comprise a metal ormetal alloy. The frame structure may also include a raceway at least ata bottom of the frame structure for receiving electrical wiring. Each ofthe at least one electrical socket may be configured to receive a twoprong connector.

The hollow tube may be an aluminum extrusion. In one embodiment herein,first ends of the end cap bodies may define an area configured toreceive one of the first or second ends of the hollow tube, wherein eachof the first end and the second end of the hollow tube fits securelywithin the respective area of each of the first ends of the end capbodies of each of the first and the second rotatable end caps.

The exterior surface of the hollow tube in a further embodiment maycomprise a pair of spaced apart flanges that each define at least oneinwardly facing channel shaped to receive longitudinally extendingopposite side edges of the circuit board. The assembly may furthercomprise at least one longitudinally extending diffuser shaped to fitover the circuit board and the plurality of light emitting diodes,wherein the pair of spaced apart flanges each further defines anoutwardly facing channel shaped to receive the diffuser. Further, twocircuit boards may be provided to the assembly, and in such anembodiment, the exterior surface of hollow tube may comprise two pairsof the spaced apart flanges, wherein the inwardly facing channels ofeach pair of the spaced apart flanges are shaped to receive thelongitudinally extending opposite sides of one of the circuit boards.Two longitudinally extending diffusers may also be provided whichpreferably each are shaped to fit over one of the circuit boards and theplurality of light emitting diodes, wherein each pair of spaced apartflanges each further defines an outwardly facing channel shaped toreceive one of the diffusers.

The light emitting diodes may have a lens provided over each of thelight diode chips. Such a lens may include one or more mounting legs forspacing the lens above one of the light diode chips.

The socket cap of the assembly may include two holes. Further the plugmay have two connectors, which may be prong connectors. The at least oneconnector is preferably in electrical communication with the socket andalso with a conductive material in electrical communication with thecircuit board through wiring extending from the conductive materialthrough the rotatable end cap assembly. In addition to light emittingdiode chips, the assembly may further comprise at least one lightemitting diode component such as a power supply situated within thehollow tube in electrical communication with the plurality of lightemitted diodes. The wire preferably extends through the longitudinallyextending opening between the projections of the cam locking mount,through the passageway in the rotation cam and through thelongitudinally extending passageway of the bore in the rotatable end capbody and through the first end of the end cap body.

In a further embodiment, the longitudinally extending bore of the endcap body may extend beyond a perimeter edge of the second end of the endcap body. The inner facing surface of the collar of the end cap body mayalso have a plurality of recesses shaped to successively receive anoutward extending feature on a side edge of the first end of therotation cam for controlled rotation. The interior facing side of thecam locking mount preferably also has a surface extending at leastpartially peripherally around the longitudinally extending projectionsof the cam locking mount and at least one stop feature on the surfacefor engaging a recess proximate an edge of the inner surface of thesecond end of the end cap body of the rotatable end cap so as to limitrotation of the rotatable end cap.

The plug body may be secured to the cam locking mount by at least onefastener, which may be at least one screw, and at least one of the plugbody and the cam locking mount may also include a screw receiving borewhile the other has a through opening aligned with the bore. Therotatable end cap may also include at least one screw receiving bore andthe hollow tube include at least one inwardly fastener receivingextension for securing the rotatable end cap to the hollow tube by wayof at least one fastener, wherein the at least one fastener may be ascrew.

The invention further includes a light emitting diode light tube whichis preferably the light emitting diode light tube in the sign assemblyas described above.

The invention also includes a method for retrofitting at least one lightemitting diode light tube in a sign assembly comprising at least onefluorescent light tube, comprising: (a) providing a sign assembly havingat least one fluorescent light tube having a connector on each end, atleast one translucent plate, a frame structure securing a perimeter ofthe at least one translucent side plate, the frame structure having aninterior surface having at least two opposite sides spaced from eachother, at least two electrical sockets, each for receiving one of theconnectors on the ends of the at least one fluorescent light tube, andwiring for connecting the electrical sockets through a ballast and to anelectrical source; (b) opening the sign assembly so as to access the atleast one fluorescent light tube and to the ballast; (c) disconnectingwiring extending between the electrical sockets on either side of thefluorescent tubes and the ballast to create disconnected ends on wiresextending from the electrical sockets; (d) connecting the disconnectedends to create an electrical bypass around the ballast; (e) removing theat least one fluorescent tube; and (f) installing at least one lightemitting diode light tube having a connector on each end thereof in theelectrical sockets to form a retrofit sign assembly.

Each end of the at least one light emitting diode light tube preferablyhas a rotatable end cap assembly on each end thereof comprising theconnectors, and the method further comprises rotating the rotatable endcap assemblies of the at least one light emitting diode light tubebefore or after step (f) so that the light emitting diode light tubewill direct light in a desired direction within the retrofit signassembly.

In one embodiment, in step (a), the sign assembly comprises two or morefluorescent light tubes and in step (f) two or more light emitting diodelight tubes are installed to replace the two or more fluorescent lighttubes removed in step (e), and before or after step (f) the rotatableend cap assemblies of the each of the two or more light emitting diodelight tubes are rotated to direct light in a desired direction withinthe retrofit sign assembly. The two or more light emitting diode lighttubes may be rotated in different directions.

The rotatable end cap assemblies of the invention herein and preferablyeach comprise: a socket cap defining at least one hole extendinglongitudinally therethrough; a plug having a plug body, wherein theconnector extends longitudinally from an exterior end of the plug body,and the connector is configured to pass through the at least one hole inthe socket cap, the plug body having on an interior end thereof, aninterior surface defining an interior space therein; a rotatable end caphaving an end cap body with a first end and a second end, the first endof the end cap body configured to engage one of the ends of a tubeportion of the light emitting diode light tube and the second end of theend cap body having an inner surface defining a recess, at least onelongitudinally extending bore extending through the rotatable end capand through the recess of the second end of the end cap body, the boredefining a longitudinal passageway, and a longitudinally extendingcollar situated between the inner surface of the rotatable end cap andthe longitudinally extending bore, wherein the plug body is configuredto be received at least partially within the second end of the rotatableend cap; a cam locking mount having an exterior facing side configuredto be positioned within the interior space of the plug body and aninterior facing side having longitudinally extending projectionsconfigured to be received within the longitudinally extending bore ofthe rotatable end cap and to form a longitudinally extending openingbetween the projections in general alignment with the longitudinalpassageway through the bore of the rotatable end cap; a rotation camhaving a tubular shape defining a passageway extending therethrough, afirst end and a second end, the first end positioned in the recess ofthe second end of the rotatable end cap between the collar and the boreof the rotatable end cap, wherein an inner facing surface of the collaris configured to receive and engage the first end of the rotation cam,the second end of the rotation cam configured to be received within thecam locking mount around the projections thereof, and wherein therotatable end cap is capable of controlled rotation with respect to theplug body and cam locking mount by rotation of the rotation cam withinthe collar.

In one embodiment of the method above, the method preferably includesshutting the power prior to step (b) and turning the power on after step(f).

The sign assembly used in the method preferably has two translucentplates and the method further comprises removing at least one of theplates to access the fluorescent light tubes. In one embodiment of themethod, the wires in the light assembly in step (a) are positioned in araceway in a lower portion of the frame below a cover, and the methodfurther comprises removing the cover to access the wires prior to step(c).

The invention also includes a method for installing at least one lightemitting diode light tube having rotatable end cap assemblies on eitherend thereof in an LED-ready sign assembly, comprising: (a) providing asign assembly having at least one translucent plate, a frame structuresecuring a perimeter of the at least one translucent side plate, theframe structure having an interior surface having at least two oppositesides spaced from each other, at least two electrical sockets, each forreceiving connectors on the ends of at least one light emitting diodelight tube, and wiring for connecting the electrical sockets to anelectrical source; (b) providing at least one light emitting diode lighttube having a first end and a second end and having a rotatable end capassembly positioned on each of the first and the second end of the atleast one light emitting diode light tube, wherein the rotatable end capassembly has a connector extending from one end thereof; (c) opening thesign assembly so as to access the electrical sockets; (d) rotating therotatable end cap assemblies on the first and the second ends of one ofthe at least one light emitting diode light tube; and (e) installing theat least one light emitting diode light tube such that each of theconnectors on each of the ends of the rotatable end cap assemblies ofthe light emitting diode light tube are positioned in electricalcommunication with the electrical sockets to form a light emitting diodelight tube sign assembly.

In this method, in one embodiment, the method further comprises rotatingeach of the rotatable end cap assemblies after step (e) so that thelight emitting diode light tube will direct light in a desired directionwithin the light emitting diode light tube sign assembly. In step (b),two or more light emitting diode light tubes may be provided, in step(e) two or more light emitting diode light tubes may be installed, andbefore or after step (e) the rotatable end cap assemblies of the each ofthe two or more light emitting diode light tubes may be rotated todirect light in a desired direction within the light emitting diodelight tube sign assembly. Further, the two or more light emitting diodelight tubes may be rotated in different directions.

In the method, each of the rotatable end cap assemblies may comprise: asocket cap defining at least one hole extending longitudinallytherethrough; a plug having a plug body, wherein the connector extendslongitudinally from an exterior end of the plug body, and the connectoris configured to pass through the at least one hole in the socket cap,the plug body having on an interior end thereof, an interior surfacedefining an interior space therein; a rotatable end cap having an endcap body with a first end and a second end, the first end of the end capbody configured to engage one of the ends of a tube portion of the lightemitting diode light tube and the second end of the end cap body havingan inner surface defining a recess, at least one longitudinallyextending bore extending through the rotatable end cap and through therecess of the second end of the end cap body, the bore defining alongitudinal passageway, and a longitudinally extending collar situatedbetween the inner surface of the rotatable end cap and thelongitudinally extending bore, wherein the plug body is configured to bereceived at least partially within the second end of the rotatable endcap; a cam locking mount having an exterior facing side configured to bepositioned within the interior space of the plug body and an interiorfacing side having longitudinally extending projections configured to bereceived within the longitudinally extending bore of the rotatable endcap and to form a longitudinally extending opening between theprojections in general alignment with the longitudinal passagewaythrough the bore of the rotatable end cap; a rotation cam having atubular shape defining a passageway extending therethrough, a first endand a second end, the first end positioned in the recess of the secondend of the rotatable end cap between the collar and the bore of therotatable end cap, wherein an inner facing surface of the collar isconfigured to receive and engage the first end of the rotation cam, thesecond end of the rotation cam configured to be received within the camlocking mount around the projections thereof, and wherein the rotatableend cap is capable of controlled rotation with respect to the plug bodyand cam locking mount by rotation of the rotation cam within the collar.

The method for installation preferably further comprises shutting thepower prior to step (c) and turning the power on after step (e).

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

The foregoing summary, as well as the following detailed description ofpreferred embodiments of the invention, will be better understood whenread in conjunction with the appended drawings. For the purpose ofillustrating the invention, there is shown in the drawings embodimentswhich are presently preferred. It should be understood, however, thatthe invention is not limited to the precise arrangements andinstrumentalities shown. In the drawings:

FIG. 1 is a perspective view of a rotatable LED light tube according toan embodiment of the invention;

FIG. 2 is a an exploded view of the rotatable LED light tube;

FIG. 3 is a transverse cross-sectional view of the LED light tube of theembodiment of FIG. 1 as shown in FIG. 4 and taken along lines 3-3;

FIG. 4 is a partially broken, enlarged view of an end cap assembly onthe rotatable LED light tube of FIG. 1;

FIG. 5A is an exploded exterior end perspective view of an embodiment ofthe rotatable end cap assembly for use in the LED light tube accordingto FIG. 1;

FIG. 5B is an exploded interior end perspective view of the embodimentof the rotatable end cap assembly of FIG. 5A;

FIG. 6A is an exterior plan view of a socket cap of the embodiment ofthe rotatable end cap assembly of FIG. 5A;

FIG. 6B is an interior plan view of the socket cap of FIG. 6A;

FIG. 7A is an exterior plan view of a plug of the embodiment of therotatable end cap assembly of FIG. 5A;

FIG. 7B is an interior plan view of the plug of FIG. 7A;

FIG. 8A is an exterior plan view of the cam locking mount of theembodiment of the rotatable end cap assembly of FIG. 5A;

FIG. 8B is an interior plan view of the cam locking mount of FIG. 8A;

FIG. 9A is an exterior plan view of a rotation cam of the embodiment ofthe rotatable end cap assembly of FIG. 5A;

FIG. 9B is an interior plan view of the rotation cam of the FIG. 9A;

FIG. 10A is an exterior plan view of the rotatable end cap of theembodiment of the rotatable end cap assembly of FIG. 5A;

FIG. 10B is an interior plan view of the rotatable end cap of FIG. 10A;

FIG. 10C is an exterior plan view of a subassembly of the rotatable endcap and rotation cam of the rotatable end cap assembly of the embodimentin FIG. 5A;

FIG. 11 is an exterior perspective view of the rotatable end capassembly of FIG. 5A;

FIG. 12A is an open view of a two-sided sign light box assembly havingfluorescent tube lights installed therein and one translucent panelremoved;

FIG. 12B is a view of the sign light box assembly of FIG. 12A with thewiring in connection with the fluorescent tubes and ballast beingdisconnected from the ballast and by-passing the same;

FIG. 12C is a view of the sign light box assembly of FIG. 12A with thefluorescent light tubes removed;

FIG. 12D is a view of the sign light box assembly of FIG. 12A with LEDlight tubes according to an embodiment of the invention installed inplace of fluorescent tubes;

FIG. 13A is a perspective top view of a lens for an LED light for use inan embodiment of an LED light tube of the invention;

FIG. 13B is a bottom perspective view of the lens of FIG. 13A; and

FIG. 13C is a longitudinal cross-sectional view of the lens of FIG. 13Ataken along line 13C-13C of FIG. 13A.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is intended to provide furtherdetails to the invention described in the claims and shown in theDrawings. Light emitting diode (LED) light tubes, and methods forinstalling the same in sign assemblies which are LED-ready, i.e.,already configured for use with LED light tubes, and methods forretrofitting LED light tubes in existing sign assemblies designedinitially for use with fluorescent light tubes are described furtherherein according to preferred embodiments of the invention.

As used herein, words such as “inner” and “outer,” “interior” and“exterior,” “upper” and “lower,” “outside” and “inside,” “top” and“bottom,” “left” and “right,” “inwardly” and “outwardly” and words ofsimilar import are intended to assist in understanding preferredembodiments of the invention with reference to the accompanying drawingFigures and with respect to the orientation of the sealing assemblies asshown in the Figures, and are not intended to be limiting to the scopeof the invention or to limit the invention scope to the preferredembodiments shown in the Figures. The presence of multiple embodimentsherein use like reference numbers to refer to analogous features of theinvention as described herein and as shown in the drawings, such thatabsent language to the contrary describing an alternative configurationfor a particular feature, one skilled in the art would understand, basedon this disclosure and the drawings attached hereto, that description ofone such feature is applicable to an analogous feature in anotherembodiment herein unless otherwise specified. Further, words in theclaims and specification hereof are intended to have their ordinarymeaning to one skilled in the art as amplified or clarified by anyfurther application-specific information, in the absence of an express,applicant-provided definition.

An LED light tube according to a preferred embodiment herein isdescribed with reference to FIGS. 1-11 and 13A-13C. As shown in FIG. 1,the preferred embodiment described is referred to generally as LED lighttube 100. The LED light tube 100 as shown has a hollow tube 102. Thehollow tube may be formed of any of a number of materials known for usefor light tubes in the art or to be developed for such purposes. Thelight tube may itself be transparent, opaque or translucent and can beused as both a tube and diffuser for LED light simultaneously, in whichcase the entire light tube would surround and cover the LED light chipsand any accompanying lens. Alternatively, the hollow tube 102 may bemade as a separate extrusion equipped to mount or hold any related LEDparts and optional lens and diffusers. It should be understood to oneskilled in the art, based on this disclosure that while a preferredlight tube assembly for the visual aspects is shown for the purpose ofdemonstrating the invention, the light tube may be varied and used withthe novel rotatable end caps described herein, and also be within thescope of the invention.

In a preferred embodiment as shown, the LED light tube's hollow tube isshown as an extrusion, so as to hold and mount other items in the LEDlight tube 100. The hollow tube 102 can be extruded or otherwiseheat-molded of formed using metal, metal alloy or composite materialwhich may optionally include conductive fillers or conductiveparticulate reinforcement. Suitable materials used include aluminum,aluminum alloys, glass, silicon-based polymers, polycarbonate,reinforced polyolefins, reinforced polyarylene ether materials and thelike. Preferably, the hollow tube has high thermal conductivity andstrength and is able to act as a heat sink to dissipate heat from theapparatus and/or includes a conductive material for charge dissipationor conduction as desired. In one embodiment, the extrusion is alightweight aluminum or aluminum alloy material.

The hollow tube 102 is preferably shaped so as to provide one or moreexternal features for securing the LED chips and related LED-functionalparts as described further below. It is also preferably hollow both toreduce weight as well as to store operational component(s) 104 of theLED light tube 100, such as internal power supply or transformer shownrepresentatively as component(s) 104, wiring and any other functionalcomponents as desired and as are known or to be developed in the art.Accordingly, the hollow tube 102 preferably includes a longitudinallyextending passageway 106 that runs from a first end 108 of the hollowtube 102 to the second end 110 of the hollow tube. The exterior surface112 of the hollow tube 102 is configured to have features 114 to seat acircuit board 116.

In one embodiment, the features 114 as shown are configured as a pair ofspaced apart flanges 118 that are inwardly facing so as to define aninwardly-facing channel 120 shaped to receiving longitudinally extendingopposite edges 122 of the circuit board 116. Such features 114 may alsobe modified to interact with an optional outer housing and/or diffuser124. The optional outer housing 124 may be a translucent, transparent,or opaque material which is preferably strong and consistent in physicalproperties, and also preferably lightweight. Suitable materials includepolycarbonate or glass.

The optional outer housing may be formed and have a clarity level so asto diffuse light coming from the LED chips on the printed circuit board.If so, optional housing 124 may be referred to also herein as diffuser124. The diffuser 124 may be shaped to give an overall generallycircular profile to the LED light tube and may be positioned on oneportion of the hollow tube 102 or on more than one location on thehollow tube 102. As shown in the preferred embodiment herein, twodiffuser housings are incorporated onto opposing sides of the hollowtube. To accommodate one or more such diffusers 124 shaped to fit overthe circuit board 116 and the light emitting diodes, the features 114(or other optional features if desired) may be modified further toinclude a pair of spaced apart flanges 126 that are outwardly facing soas to each define an outwardly facing channel 128. The diffuser 124 maythus be shaped such that on either side thereof, the outwardly facingchannels 128 are each configured to receive the diffuser 124. As shown,the diffusers each have inwardly facing edges 130 that fit within thechannels 128 to allow for a slidable construction which securely mountsthe diffusers to the hollow tube 102.

In the embodiment shown, there are two circuit boards 116, such that theexterior of the hollow tube 102 includes features 114 on more than onelocation as described above. As shown in FIG. 3, such features 114 areon opposite sides of the hollow tube and incorporate inwardly facingflanges 118 and outwardly facing flanges 126, each defining respectivelyinwardly facing channels 120 and outwardly facing channels 128. Theinwardly facing channels 120 accommodate the circuit boards 116, and theoutwardly facing channels 128 receive inwardly directed edges 130 ofdiffusers/housing 124 to create an overall generally circular profile tothe LED light tube 100. Each of the circuit boards used includes one ormore light emitting diode chips 132. Preferably, a plurality of suchchips 132 are provided. While two circuit boards 116 are shown, itshould be understood that the hollow tube could be shaped in crosssection to have four or more accommodating areas on the exterior surface112 of the hollow tube 102. For example, if the hollow tube has atransverse cross-sectional shape that was more of a complete rectangle,or a triangle, a pentagon, a hexagon, etc., then the outer housing whichmay be a diffuser could be configured to fit completely over all sidesas a single unit or configured to slide over each side in a manner asdescribed above. The benefit of the present invention, is that howevermany circuit boards are provided (only one or two, three, four, etc.),the rotatable end cap assemblies as described further below, allow forself-positioning of the light direction, such that the LED light tubesmay be used for maximum effects and illumination by rotating the tubesto shine light in a desired direction. By doing so, one can minimize thenumber of areas on the LED light tube requiring LED light chips, as eachof the LED light tubes may be positioned facing varied locations, andmultiple sided use to achieve the same effect is not necessary, even ifthe design can accommodate it. Thus, while not necessary, the LED lighttube design herein may be made to have one, two, three or more circuitboards mounted on the outside thereof.

The LED chips themselves and the circuit board(s) are preferably inelectrical communication, i.e., they are electrically connected throughconductive material to one another directly or indirectly throughanother electrical component and/or are each in electrical communicationwith connectors as described further below that are connectible to anelectrical power source. The circuit boards may include conductivematerial and/or wire to act as heat sinks and also dissipate LED heatand energy in the same manner as the hollow tube 102. Each of thecircuit boards can accommodate a plurality of LEDs. As is customary inLED strips and other LED mounted tubes, multiple smaller lower wattageLEDs may be used or likely fewer larger, higher wattage LEDs may beused. The LEDs are preferably spaced uniformly. The LEDs may be mountedto the circuit boards using any suitable technique known or to bedeveloped in the art. Preferably, the LEDs are mounted to the circuitboard 116 by use of surface mount technology (SMT) soldering technology.Spacing 134 of LED chips 132 is preferably about 1.25 in. (3.18 cm) formost LED light tubes, but the distance can be varied based on the LEDchips selected and the desired illuminance. Preferred distances betweenLED chips range from about 0.625 in. (1.588 cm.) to about 2.0 in. (5.08cm) from center to center. LED chips are a nominal 1 W LED in preferredembodiments described herein. However, it is possible also to use 0.2 Wto 0.5 W nominal LED chips within the existing invention as well, andthe invention may also be modified should other LED chip sizes, powercapacity and illuminance properties be developed.

In a preferred embodiment herein, one or more of the LED chips 132, andpreferably all of them, is covered by a lens 136. The lens may be any ofa variety of lenses available for use with LED chips. Preferably thelens is one that provides a wide array of light angle diffusion for eachLED chip. As shown best in FIGS. 3 and 13A-13C, the lens 136 has acurved upper surface for directly the light outwardly. One or moresupporting mounting legs 138 are provided for spacing the lens 136 abovean LED chip 132. The mounting legs allow the lens to sit above thesurface of the printed circuit board and over a top 139 of the LED chip132 for allowing heat to escape and for mounting on the circuit board.As best shown in FIGS. 13B and 13C, the bottom surface 141 of the lensincludes an internal portion 140 that defines a cavity 142. The cavitywhich as shown is a somewhat pointed dome-like structure allows forspacing from the LED chip 132 and the curvature thereof also helps fordispersing light in wider directional paths toward the curved outersurface as light moves from within the lens 136 to an area outside thelens prior to leaving through the housing which may be a diffuser 124.Multiple lenses are preferably provided such that each LED chip used hasits own lens.

As shown in FIGS. 1-11, each of the LED lighting tubes 100 has arotatable end cap assembly. A first and a second rotatable end capassemblies 144, 146 are shown in the drawings. For purposes ofexplanation, while each of assemblies 144 and 146 is positioned on afirst end 108 and a second end 110 of the LED hollow tube 102,respectively, as each are preferably the same, description of bothassemblies is made with reference to assembly 144 as shown inperspective view in FIG. 11.

With reference to the rotatable end cap assembly as shown in FIG. 11,the assembly includes a socket cap 148, a plug 150 and a rotatable endcap 152. Each can be seen from the outer surface 153 of the rotatableend cap assembly. Each end cap assembly 144, 146 is able to rotate abouta longitudinal axis A-A′ running through the LED light tube and each endcap assembly. Rotation can be configured to be in either direction. Asshown by arrow B, rotation occurs around the axis A-A′. As shown inFIGS. 5A and 5B, each assembly is mounted respectively on the first andsecond ends of the hollow tube as noted above. Each assembly comprisesin addition to the socket cap 148, plug 150 and rotatable end cap 152, acam locking mount 154 and a rotation cam 156.

The socket cap 148 and plug 150 operate together to provide electricalconnection to an electrical socket in a light fixture into which the LEDlight tube is to be installed. With reference to FIGS. 4-6B, the socketcap 148 includes at least one hole 158 for receiving a connector 174 ofthe plug 150. As shown, two such holes 158 are openings extending fromthe bottom surface 160 of the socket cap 148 up through an extendingportion 162 of the socket cap. The connector(s) 174 once inserted in theholes 158 will connect with conductive material 164 positioned toreceive and contact the connector(s) 174 for carrying current from thesocket 150 into the LED light tube. A further opening 166 is formed inthe center of the extending portion 162 of the socket cap 148. The base168 of the socket cap 148 is configured to fit over the top surface 170and edges 172 of the plug 150, preferably in mating engagement, althoughdirect physical contact along the entire surface 170 is not necessary.

With reference to FIGS. 5A, 5B, 7A and 7B, the plug 150 is shown ashaving connector(s) 174 and plug body 176 with an exterior end 178 andan interior end 179. The connector(s) as shown include two suchconnectors 174 in the form of prong(s) 175 extending longitudinally froman exterior end 178 of the plug body 176 of the plug 150. The prongs 175or other connectors as may be used and as noted above pass through theholes 158 in the socket cap 148 and contact the conductive material 164in the socket cap on one end 177 of the prong 175 connector(s) 174. Theplug 176 body has a lower, interior facing surface 180 on the interiorend 179 of the plug body 176. The interior facing surface defines aninterior space 182.

The interior-facing, other end 184 of the prong connector(s) contactsfurther conductive material 164 positioned on the lower, interiorsurface 180 of the plug body 176. At least one of the plug body 176 andthe cam locking mount 154 are each configured to be secured together.The two parts may be fastened to be secured in any typical manner suchas by adhesive, snap fit connectors, interlocking tabs, projections andmating grooves and the like. As shown in the preferred embodimentherein, one or both of the cam locking mount and the plug body is shapedto receive a fastener such as a screw. As shown, a screw receiving bore186 is formed on the interior surface 180 of the plug body and definesan opening 188 therein for receiving a screw 190. The cam locking mount154 as shown includes a mating hole 192 formed in another bore on thecam locking mount for receiving the screw 190. One skilled in the artwould understand based on this disclosure that the parts could also bereversed putting the receiving bore on the cam locking mount and thehole on the plug body such that the fastener could be directed in eitherdirection on the assembly. As shown, two such fasteners are provided onthe plug body and cam locking mount. In addition, one or more guides 193may be provided on the interior surface 180 of the plug body to positionthe cam locking mount for securing the two together.

With references to FIGS. 5A, 5B, 10A, 10B and 10C, the rotatable end cap152 has an end cap body 194 having an interior first end 196 and anexterior second end 198. As shown in FIGS. 5B and 10B, the first end 196is configured to engage one of the first or the second ends of thehollow tube 102. As shown in FIGS. 2-4, one end 108 of the tube 102 issized and configured to fit securely in an area 191 defined within theinterior first end 196 of the end cap body. Each end 106, 108 of thetube 102 may fit within respective areas 191 within each of the firstends 196 of the end cap bodies 176 of each of the rotatable end capassemblies 144, 146. Depending on the shape of the hollow tube, anadditional housing may be provided or partial housing as shown, whereinthe partial housing is also a diffuser(s) 124. The overall structure ofthe hollow tube and attached components fits within the area 191 of theend 196 of the end cap body. As shown, the end 196 has a slightlybeveled edge 200 for receiving the tube. A further guide bevel 202 maybe provided as well for positioning the end 108 of the hollow tube 102into the first end 196 of the end cap body 194.

The second end 198 of the end cap body 194 is characterized by a formedsurface having numerous features thereon. An inner surface 204 of thesecond end 198 which runs along the inside of the second end 198 definesa general recess 206 therein, i.e., an area that is defined at leastpartially within the confines of the second end 198 as described furtherherein. The inner surface 204 defines at least one longitudinallyextending bore 208 that extends through the rotatable end cap throughthe inner surface 204 through the recess 206 and terminates eithersubstantially in line with or extending interiorly beyond a perimeteredge 197 of the second end 198 of the end cap body 194. Thelongitudinally extending bore 208 defines a passageway 210 therethrough.The inner surface 204 also defines a longitudinally extending collar 212which is situated within the recess 206. The collar 212 is preferablysituated between the inner surface 204 and the longitudinally extendingbore 208 and is preferably spaced inwardly from a side portion 214 ofthe inner surface 204 and spaced from the longitudinal extending bore208.

The second exterior end 198 of the end cap body 194 preferably alsoincludes a stepped down or beveled exterior edge 216 configured toreceive a mating beveled edge 216 on the plug body 176 of the plug 150,wherein the plug is preferably seated within the rotatable end cap 152.Thus the plug body 176 is configured so as to be received at leastpartially within the second end 198 of the rotatable end cap. Otherconfigurations for seating the plug body and the rotatable end cap mayalso be used, such as reversing the ends, having one piece slide withinthe other using mating pieces and the like. However, for rotationalpurposes it is preferred that the two pieces are seated so as to berotatable with respect to one another and to have slidable end surfaceswhere the edges are seated. It is preferred that the end cap body, theplug body and the socket cap are all formed of a moldable thermoplasticmaterial that is suitable for use with electrical components, such as aconductive polyolefin, a polyarylene, polyarylene ethers, polycarbonate,an acrylonitrile-butadiene-styrene, a polyimide, polyetherimide,polystyrene or the like. It is also preferred that the parts are durableand have good frictional and strength properties.

The collar 212 noted above is preferably configured to include a surface218 facing the longitudinal axis of the LED light tube that has one ormore engaging features 220 thereon. As shown the features formed areconcave curved surfaces in succession around the surface 218. Suchfeatures may be varied, but are preferably shaped so as to successivelyreceive and engage outward extending feature(s) described below on afirst side edge of the first end of the rotation cam 156 for controlledrotation.

The end cap body may also include one or more fastener receiving bores222 having an opening 224 therein, such as for receiving one or morefasteners. An additional optional opening 260 for a bore is alsoprovided. For example, as shown, fasteners may be screws 226. In anoptional embodiment, as shown with respect also to FIG. 3, features 228may be provided on an interior surface 230 of the hollow tube 108. Suchfeatures may act to either engage a portion of a fastener such as screws226, act as a stop in inserting the end of the hollow tube into thefirst end 196 of the end cap body 194 or also function to run wire in asecure manner through the passageway 206 through the tube 108.Preferably, the features act to engage a portion of a fastener such asscrews 226.

The cam locking mount 154 is designed to be seated in the plug body asnoted above. The cam locking mount 154 has an exterior facing side 232and an interior facing side 234. The exterior facing side 232 isconfigured to be positioned in the interior space 182 of the plug body176 and has an opening 233 that is axially aligned through the surface235 of the exterior facing side 232. The interior facing side 234 of thecam locking mount 156 includes longitudinally extending projections 236configured to be received within the passageway 210 of thelongitudinally extending bore 208 of the end cap body 194.

Such projections 236 may be of a variety of configurations provided theycan easily and preferably snugly fit into the bore 208 and be receivedin the passageway 210 a manner in which the projections form alongitudinally extending opening 238 therebetween that is smaller thanthe opening 233 on the other side 232 of the cam locking mount 154 whencompressed and of a similar size when not compressed, but that in eithercondition is aligned axially with opening 233. The opening 238preferably is in axial alignment with the longitudinal passageway 210 inthe bore 208 of end cap body 194 of the rotatable end cap 152. Toprovide some flexibility for a variety of wiring, the opening 238 andthe bore passageway 210 are sized to receive and secure conductor wiringsuch as wire 239 running from conductive material 164, preferably formedas a wire connector 240 in the interior space 182 of the plug body 176which connector 240 is in electrical communication with the conductivematerial 164 of the socket cap and the prong connectors 175. Theprojections 236 may be formed so as to be flexible for movement of thewire in rotation while holding it securely within the passage to avoiddisconnection. The material may be formed of the same or a softer ormore flexible material than the cam locking mount 154. Such moreflexible materials may include polyolefins and similar materials, butother materials such as those noted above may be used provided theyoperate to achieve the same functional benefits. Flexible projections236 that are spaced apart and come together on pressure during insertionto form an opening 238 are shown in FIG. 5B.

The rotation cam 156 is generally of a tubular shape and preferablyformed of a more flexible material than the rotation end cap body 194and also preferably formed of a material having good sliding frictionproperties yet sufficient strength to successively engage the concavefeatures 220 on the interior surface 218 of the collar 212 of the endcap body 194. As shown in FIGS. 5A, 5B, 9A, 9B and engaged within thecollar 212 in subassembly 242 of FIG. 10C, the rotation cam has atubular shape that defines a passageway 244 that extends through therotation cam. The rotation cam has a first interior end 246 that isconfigured and sized to be positioned in the recess 206 in the secondend 198 of the end cap body 194 of the rotatable end cap 152 so that thefirst end 246 of the rotation cam 156 is positioned between the collar212 and the longitudinally extending bore 208 of the rotatable end cap152. The inner surface 218 of the collar 212 having features 220 thereonis configured to be received and engage the first end 246 of therotation cam. The rotation cam 156 also has a second exterior end 248that is configured to be received in the cam locking mount 154 so as tobe situated around the projections 236 and seat within the locking mountin a rotatable manner.

Thus, the wire 239 or other wiring in the rotatable end cap, extendslongitudinally through the longitudinally extending opening 238 betweenthe projections and also through the passageway 244 of the rotation cam156 and through the opening 233 in the exterior facing end of the camlocking mount and further through the passageway 210 in the bore 208 ofthe rotatable end cap body and then through the interior facing end 196of the rotatable end cap body so as to connect to additional wiring 238extending through hollow tube and in electrical communication with theinternal electronic components of the LED light tube such that the LEDchips, circuit boards, LED light tube electronic components and therotatable end caps are all in electrical communication through thesocket caps with sockets for receiving the LED light tube. One skilledin the art, based on this disclosure would also understand that the atleast one connector(s) 174 in the form as shown of two prongs 175 are inelectrical communication with a conductive material 164 through whichthe rotatable end cap assemblies 144, 146 are also in electricalcommunication with the socket designed for receiving the LED light tubeand also through wiring extending through the rotatable end cap assemblyfrom conductive material 164 in connector 240 such that the connector(s)174 are also in electrical communication with the circuit board and LEDchips and other LED components in the light tube.

The rotatable end cap 152 by way of the end cap body 194 is capable ofcontrolled rotation with respect to the plug body 176 of the plug 150and the cam locking mount 154 by rotation of the rotation cam 156 withinthe collar 212. The second end 248 of the rotation cam 156 has featuressuch as slots 250 that that hold the rotation cam 156 stationary in thecam locking mount 154. Thus, when the plug, socket cap, cam lockingmount and rotation cam, all move as one assembly with respect to therotation end cap. As the rotation cam 156 moves, an outward extendingfeature 252 on a side edge 254 of the first end 246 of the rotation cam156 can be successively received in features 220 on the inner surface218 of the collar 212. As shown, the concave features 220 are configuredto receive an engage a convex projection shown as feature 252 on thefirst end 246 of the rotation cam 156. The successive engagementprovides a controlled rotation over 360 degrees.

In one embodiment hereof, rotation can be constrained further to lessthan 360 degrees, including less than 190 degrees and less than 180degrees if desired by way of an additional stop feature. A stop 256 maybe provided to a surface 258 of the interior facing side of the camlocking mount. The surface 258 preferably extends at least partiallyperipherally around the longitudinally extending projections 236 of thecam locking mount 154. There may be more than one stops 256 as welldepending on the rotational effect desired. The at least one stop 256projects upwardly from the surface 258 and can be arranged to engageareas 263 between web feature(s) 262, although other interactive stopfeatures may be used. The web features 262 are positioned in the recessproximate the edge 216 of the inner surface 204 of the second end 198 ofthe end cap body 194 of the rotatable end cap 152.

In use, the light tube assemblies 100 of the present invention may beinstalled in a new sign assembly having sockets capable of receiving LEDlight tube assemblies preferably including the light tube assemblies 100herein. In addition, the LED light tube assemblies herein having therotatable end cap assemblies as described may be used for installationin a sign assembly comprising at least one fluorescent light tubethrough a retrofitting method. In each case, the method will bedescribed with respect to a representative sign assembly 300. However,with respect to the method of installing LED light tubes as describedherein into a new LED-ready sign assembly, the light assembly 300 wouldinclude LED-ready sockets and would not incorporate a fluorescent lightballast as shown and described herein with respect to FIGS. 12A-12D. Thegeneral structure and frame of the assembly are otherwise the same suchthat for brevity, FIGS. 12A-12D will be used for reference for bothinstallation methods.

In a method for retrofitting at least one LED light tube herein in asign assembly, such as assembly 300, in a first step, a sign assembly300 is provided which includes at least one light tube 302 having aconnector 304 in a connector end of the tube 302 which may be anyconnector used by those skilled in the art. Preferably, in theretrofitting method, the connector is a standard connector as is used inan existing fluorescent light tube for a sign assembly and the lighttube 302 is a fluorescent light tube. Typical fluorescent light tubesused for this purpose are T8HO and T12HO type tubes. The LED light tubes100 of the invention herein may replace existing fluorescent tubes anduse existing R17d ANSI base fluorescent lamp holders and sockets alreadyin place in the sign assembly 300.

The sign assembly 300 has at least one fluorescent tube in a preferredretrofitting method embodiment. It further includes at least onetranslucent side plate 306, and a frame structure 308 capable ofsecuring a perimeter 310 of the at least one translucent side plate 306.The frame structure and translucent side plate(s) may have a variety ofperimeter shapes so as to accommodate a variety of sign assemblydesigns. As shown, the frame and plate are a simple box design. Oneskilled in the art would understand based on this disclosure that morecomplex signs of varying shapes may be made provide opposing sides ofthe frame structure include or are extended through internal framing toinclude electrical sockets in tube holders within the frame. As shown,the frame structure 308 has an interior surface 312 having at least twoopposite sides 314 spaced from each other.

The sides 314 each include light tube holders having sockets 316 thereinfor receiving connectors 304 inside thereof for electricalcommunication. The light assembly further includes wiring 318 forconnecting the electrical sockets/holders 316 through a ballast 320 toan electrical source 322. Such fluorescent light assemblies are wellknown in the art and are shown here only in a representative manner forpurposes of explaining the method steps herein.

In the method, preferably, the power is shut off to the sign assemblybefore beginning. The open side area 324 could also include a secondtranslucent plate 306 thereon or could have a solid removable backing.One or both of the plates are removed or the backing removed to open thesign assembly so as to access the at least one fluorescent light tube302 as in FIG. 12A. If a raceway 326 is present and has a cover over theballast 320 as are known in the art, the cover should be removed toexpose the raceway 326 and wiring 318. The wiring around the ballastthat extends to each side to the electrical sockets is then disconnectedas shown in FIG. 12B. The wires are capped. The disconnected ends 328created by the disconnection step on one side of ballast 320 of the signassembly are connected and capped and joined to a bypass wire 330connected to at least one of the other disconnected wires 332 on theopposite side of the ballast, creating an electrical bypass of theballast as shown in FIG. 12B. The fluorescent tubes are then removedleaving an empty sign assembly with lamp holders with open sockets 316as in FIG. 12C.

At least one LED light tube such as LED light tubes 100 of the presentinvention is installed in the sign assembly 300 with each of therotatable end cap assemblies 144, 146 inserted in a socket 316 such thatconnectors 175 in socket cap 148 are capable of providing electricalcommunication to the LED light tubes 100 to form a retrofit light tubeassembly 300A as shown in FIG. 12D. Each of the LED light tubes 100incorporated in the LED retrofit light tube assembly 300A preferablyincludes on each end the rotatable end cap assemblies as described inpreferred embodiments herein. The method may further comprise rotatingone or more of the LED light tubes by way of the rotatable end capassemblies thereon before or after installing the LED light tube(s) inthe sign assembly. That is, one may pre-position the direction of theLED light chips before installation by use of the rotatable end caps, ormay install the tubes and then rotate them while the socket cap orexterior end of the rotatable end cap assembly is stationary in thesocket 316 and the rotatable end cap is moved along with the hollow tube102 and related features while installed within the frame 308. Thiscapability allows for positioning the LED light tubes to provide desireddirection for the sign assembly for a variety of lighting effects.

In a retrofit assembly 300A, two or more LED light tubes 100 may beinstalled. Two are shown for illustrative purposes in FIG. 12D. In sucha configuration each of the light tubes, just one of the tubes or anynumber thereof may be rotated before or after installation for similareffects and optimal lighting, which is particularly useful in a two-sidesign assembly having two translucent plates 306. For two-sided signassemblies, it is desirable to rotate LED light tubes in opposing ordiffering directions to adequately light both sides of the signassembly.

Once the light tubes are installed, the raceway cover (if any) may bereplaced to protect the wiring and any back cover or second translucentplate re-installed to complete the sign. The power may then be turnedback on for illuminating the sign assembly.

As noted above, the LED light tubes 100 herein may also be installed ina new sign assembly installation that is LED ready. With reference toFIGS. 12C and 12D, the resulting structure would be very much the samein the Figures as shown, but the ballast 320 would be omitted and theLED-ready installation sign assembly wiring would already be in placewhich omits the bypass as unnecessary. The sockets and connectors in thesign assembly may be formed initially to work with the LED light tubesherein or may be standard R17d ANSI lamp holders and sockets.

In the method for installing at least one LED light tube 100 asdescribed herein having rotatable end caps on either end of the LEDlight tube, the method would include providing a sign assembly having atleast one translucent plate, a frame structure securing a perimeter ofthe at least one translucent side plate. The frame may have an interiorsurface having at least two opposite sides spaced from each other, andat least two electrical sockets, each for receiving connectors on endsof the at least one LED light tube. Each of these features is shown inFIG. 12C with the understanding that sockets 316 need not be standardfluorescent sockets but sockets that are formed particularly for LEDlight tubes. Further, wiring provided need not be a bypass as wasdescribed for the retrofit method but can be wiring for connecting thesockets to an electrical source 322 may already configured for LED lighttubes and without the presence of ballast 320.

In the new installation method, at least one LED light tube having afirst and second end and having rotatable end cap assemblies positionedon each of the first and the second end of the at least one LED lighttube are preferably provided, wherein the rotatable end capassembly(ies) each have a connector extending from an end thereof.Preferably, each of the LED light tubes provided are configured inaccordance with LED light tubes 100 as described herein.

The sign assembly is opened (either through removal of a back panel or asecond translucent plate in a two-side sign assembly) so as to accessthe electrical sockets of the sign assembly as shown in FIG. 12C, butwith the differences noted above.

The rotatable end cap assemblies on the first and the second ends of theat least one LED light tube are rotated. This may be done before orafter installation. The at least one LED light tubes are installed suchthat the connectors on the ends of the rotatable end cap assemblies ofthe LED light tubes are positioned in electrical communication with theelectrical sockets of the sign assembly to form a LED light tube signassembly. Each of the LED light tubes in the sign assembly or only oneor a specific number thereof may be rotated to direct light in desireddirections within the LED light tube sign assembly. In a two-sided signassembly two or more LED light tubes may be rotated in opposite ordifferent directions for optimal lighting and/or enhanced lightingeffects. Once the LED light tube(s) are installed in the sign assembly,the power may be turned back on and the cover or other translucent platein the case of a two-sided light assembly by be reinstalled.

The wiring used may be 120 to 277 V AC and wired directly to the LEDlight tubes with the “hot” wires going to one end of the LED light tube(see FIG. 12B, but without the bypass wherein the “hot” wires are on theright side with the ballast omitted) and common wiring is connected tothe other end of the LED light tube (on the left side of sign assembly300 but without the bypass). No external ballast or other power supplyis needed.

The present invention thus allows for installation without the need totransform or modify existing physical components either in an LED-readynew installation or when retrofitting existing sign installations thatmay be configured for standard fluorescent light use. In retrofitting,all of the existing sockets and wiring are re-used. All that need bedone is the bypass wiring as described above such that wire line voltagegoes directly to the sockets all within the existing sign assemblycompartment.

It should be understood to those skilled in the art based on thisdisclosure that parts may be modified provided they carry out the samefunctions or generally concepts expressed in the embodiment describedherein without departing from the general scope of the invention.Colored or modified LEDs of a variety of wattage may be used as well asdifferent outer housings, modified diffusers, varying internalelectrical components for operation of the LED light tube, and varyingconductive material and connectors, each of which may be incorporatedwithin the scope of the invention.

The LED light tubes may be provided in a variety of sizes to accommodateexisting and new installation sign assemblies. LED light tube lengthscan be made to match those of existing fluorescent products that arebeing replaced including T12/T8HO lamps thereby further ensuring that noadditional modifications to the sign assembly are needed to ensure aproper fit.

The rotatable end cap LED light tubes herein may also be incorporated indifferent LED light tube end applications such as in office or interiorlighting boxes, and other known LED light tube uses. The LED light tubesherein may also be used with various optical lenses placed over the LEDchips to optimize light distribution for sign applications and other endapplications of the rotatable LED light tubes. The invention hereinfurther provides the ability to save energy through easy retrofittingover the life of the sign assembly or other structure into which therotatable LED light tubes are installed. The installation methodsprovided herein, particularly in retrofitted situations is far morequickly completed than prior art LED tube retrofitting methods.

Due to the design of the rotatable end caps as described herein,installations do not need adaptors or other modification structures toaccept or fit the LED light tubes of the present invention.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention as defined by the appended claims.

We claim:
 1. A light emitting diode (LED) light tube comprising: atubular body defining an elongated longitudinal axis, a central hollowpassageway extending longitudinally there through, at least onelongitudinally extending channel formed on an outer surface, and twoopposing tube ends; a series of individual LEDs aligned on a support ina spaced relationship and in electrical communication with one another,the support for the series of LEDs secured within the at least onechannel, and the series of LEDs having electrical connections positionedadjacent at least one of the tube ends; two end cap assemblies, one ofthe end cap assemblies positioned at each of the tube ends, each end capassembly having a first portion axially fastened to one of the tubeends, and a second portion axially secured to the first portion androtatable relative to the first portion about the longitudinal axis ofthe tubular body, the first and second portions having engaging portionsfor controlled rotation of the relative rotational movement of the firstand second portions, and a stop feature to limit the amount of relativerotation of the first and second portions; and an end connectorprojecting outwardly from the tubular body, the end connectorelectrically connected to the electrical connections of the series ofLEDs.
 2. The light emitting diode (LED) light tube according to claim 1,wherein the at least one channel on the outer surface of the tubularbody comprises a pair of spaced apart flanges, each of the flangesinwardly facing towards one another and shaped to receive opposite sideedges of the support for the series of LEDs.
 3. The light emitting diode(LED) light tube according to claim 1 further comprising at least onelongitudinally extending diffuser supported over the at least onechannel and the series of LEDs.
 4. The light emitting diode (LED) lighttube according to claim 1, wherein the tubular body comprises twochannels, one positioned on opposite sides on the outer surface oftubular body, and two supports each supporting a series of LEDs, onesupport positioned in each of the channels.
 5. The light emitting diode(LED) light tube according to claim 4 further comprising twolongitudinally extending diffusers, one diffuser secured over each ofthe two channels.
 6. The light emitting diode (LED) light tube accordingto claim 1, wherein the second portion of the end cap assembliescomprises a plug having two connectors.
 7. The light emitting diode(LED) light tube according to claim 1, wherein the end connector furthercomprises a socket cap having two holes therein, and the two projectingconnectors of the plug respectively received in one of the two holes ofthe socket cap.
 8. The light emitting diode (LED) light tube accordingto claim 6, wherein the two projecting connectors are attached to theelectrical connections for the series of LEDs, the electricalconnections formed by wiring extending through the end cap assembly. 9.The light emitting diode (LED) light tube according to claim 1 furthercomprising at least one LED power supply component situated within thehollow of the tubular body, the power supply component is in electricalcommunication with the series of LEDs.
 10. The light emitting diode(LED) light tube according to claim 1, wherein the first portion issecured to the tubular body by at least one fastener.
 11. The lightemitting diode (LED) light tube according to claim 10, wherein the atleast one fastener is a screw.
 12. The light emitting diode (LED) lighttube according to claim 10, wherein the first portion includes at leastone screw receiving bore and the tube ends include at least one inwardfastener receiving extension, the fastener engaged within the receivingbore and the receiving extension to secure the first portion to the tubeend.
 13. The light emitting diode (LED) light tube of claim 1 whereinthe first and second portions of the end cap assemblies further comprisefrictionally engaging portions for control of the relative rotation ofthe first and second portions.
 14. The light emitting diode (LED) lighttube of claim 1 wherein the end cap assemblies further comprise arotation cam positioned between the first and second portions, therotation cam having surface features frictionally engaged bycorresponding surface features on the first portion, the surfacefeatures combining for incremental rotation of the second portion aboutthe longitudinal axis of the tubular body.
 15. The light emitting diode(LED) light tube of claim 1 wherein the stop feature of the end capassemblies further comprises a limit stop, the limit stop projectingfrom one portion of the end cap assembly and engaging within a recessformed on the opposite portion of the end cap assembly during therelative rotation of the two portions about the longitudinal axis of thetubular body, the engagement of the limit stop in the recess limitingthe rotation to less than 360 degrees.
 16. A light emitting diode (LED)light tube comprising: a tubular body defining an elongated longitudinalaxis, a central hollow passageway extending longitudinally therethrough, at least one longitudinally extending channel formed on anouter surface, and two opposing tube ends; a series of individual LEDsaligned on a support in a spaced relationship and in electricalcommunication with one another, the support for the series of LEDssecured within the at least one channel in the tubular body, and theseries of LEDs having electrical connections positioned adjacent atleast one of the two tube ends of the tubular body; two end capassemblies, one of the end cap assemblies secured at each of the tubeends, each end cap assembly having a first portion axially attached toone of the ends of the tube, the first portion forming an end cap body,and a second portion axially secured to the first portion and rotatablerelative to the first portion about the longitudinal axis of the tubularbody, the second portion forming a plug body, the first and secondportions having engaging portions for controlled rotation of therelative rotational movement of the first and second portions, and astop feature to limit the amount of relative rotation of the first andsecond portions, and an end connector projecting axially outwardly fromthe plug body, at least one of the end connector electrically connectedto the electrical connections of the series of LEDs, the end cap bodyhaving a first end and a second end, the first end of the end cap bodyfixedly secured to one of the tube ends, the second end of the end capbody having an inner surface defining a recess, at least onelongitudinally extending bore defining a longitudinal passageway throughthe end cap body, the end connectors extending longitudinally from anexterior end of the plug body, the plug body having on an interior enddefining an interior surface having an interior space therein, alongitudinally extending collar situated between the inner surface ofthe second end of the end cap body and the longitudinally extendingbore, the plug body configured to be received at least partially withinthe second end of the end cap body; a locking cam mount, an exteriorfacing side of the cam mount positioned within and axially fixed to theinterior end of the plug body, an interior facing side of the cam mounthaving longitudinally extending projections configured to be receivedwithin the longitudinally extending bore, wherein the projectionsaxially fix the cam mount and the plug body to end cap body, theprojections form a longitudinally extending opening in general alignmentwith the longitudinal passageway through the bore of the end cap body,and a rotation cam having a tubular shape defining a passagewayextending there through, a first end of the cam positioned in the recessof the second end of the end cap body between the collar and the bore,an inner facing surface of the collar rotationally received by andfrictionally engaged with the first end, a second end of the camreceived in the cam mount around the projections thereof androtationally fixed thereto, wherein the engaging portions of the end capbody, the plug body, the cam mount and the rotation cam cooperate forthe controlled rotational movement of the first and second portions ofthe end cap assemblies about the tube axis.
 17. The light emitting diode(LED) light tube of claim 16 wherein the end cap assemblies furthercomprise a rotation cam positioned between the end cap body and the plugbody, the rotation cam having surface features that are frictionally andsuccessively engaged by corresponding surface features on the end capbody, the engaging surface features combining for the incrementalrotation of the plug body about the longitudinal axis of the tubularbody.
 18. The light emitting diode (LED) light tube of claim 17 whereinthe stop feature of the end cap assemblies comprises a limit stopprojecting from one portion of the end cap assembly and engaging withina recess formed on the other portion during the relative rotation of thetwo portions about the longitudinal axis of the tubular body, theengagement of the limit stop in the recess restricting the rotation toless than 360 degrees.
 19. The light emitting diode (LED) light tubeaccording to claim 16, wherein the electrical connections of the seriesof LEDs extend through an axially extending opening between theprojections of the cam locking mount, through the passageway in therotation cam, through the longitudinally extending passageway of thebore in the end cap body and through the first end of the end cap body.20. The light emitting diode (LED) light tube according to claim 17,wherein the inner facing surface of the collar of the end cap body has aplurality of recesses shaped to successively receive an outwardextending feature on a side edge of the first end of the rotation cam tocreate the incremental rotation.